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Optimization of cross section of mobile crane boom using lagrange

multiplier’s method
To cite this article: J Daniel Glad Stephen et al 2018 IOP Conf. Ser.: Mater. Sci. Eng. 402 012134

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2nd International conference on Advances in Mechanical Engineering (ICAME 2018) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 402 (2018) 012134 doi:10.1088/1757-899X/402/1/012134
1234567890‘’“”

Optimization of cross section of mobile crane boom using

lagrange multiplier’s method

J Daniel Glad Stephen*1, Arpan Banerjee2, Ashmita Lahiri2 and Ishan Mehta2
*1
Assistant Professor, SRM Institute of Science and Technology, Kattankulathur
District, Tamil Nadu, India - 603203
2
Undergraduate Student, SRM Institute of Science and Technology, Kattankulathur
District, Tamil Nadu, India - 603203

*1Corresponding Author: jdgstephen@gmail.com

Abstract. This paper discusses the optimization of cross section of telescopic boom of mobile
cranes. The extruded section is taken into consideration for the optimization problem. The
problem has been solved using Lagrange Multipliers method. The area of cross section of the
boom has been taken as the objective function, so as to minimize the mass, whereas the
constraint function has been taken as a general function of hardness and stability. The above
parameters allow us to form a mathematical model for numerical analysis and thus obtain the
optimum dimensions for the cross section.

1. Introduction
A crane is a machine which is used to lift and drop heavy materials or to move them in a horizontal
path. The basic principle of a crane is to create a mechanical advantage to the load applied such that it
is possible to lift loads a number of times heavier than what is actually possible with that effort. Over
the years, cranes have developed from a basic wire wound over a pulley, to all terrain, highly
sophisticated cranes capable of lifting up to a thousand tons. The common uses of cranes are for
loading and unloading goods, for construction and on the shop floor to aid in the assembly of heavy
components. They can be classified as follows:

The primary part of a crane is its boom. A boom is a cantilever beam, which may either be fixed or
hinged at one end. A boom consists of the following parts:[1]

1. The outermost part of the boom is known as mother boom. It consists of the remaining
sections as well as the mechanism for extension and retraction.
2. The second section of the boom is known as the middle boom. It is housed inside the mother
boom.
3. This is the third section of boom, which is inside the middle boom. The crane hook is
suspended directly from this section.

A crane boom may consist of plates welded together, or a lattice structure.[2]The boom taken under
consideration here is the former type, which is mostly employed in truck mounted, rough terrain and
all terrain cranes. A rectangular cross section is the most conventional one, where four plates are
welded together. However, higher the number of welds, higher is the chance of failure. Hence, we

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2nd International conference on Advances in Mechanical Engineering (ICAME 2018) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 402 (2018) 012134 doi:10.1088/1757-899X/402/1/012134
1234567890‘’“”

intend to minimize the possibility of failures by using only two lines of welding instead of four. To
achieve this, an extruded section may be used, with the cross-section being achieved by bending a
sheet.[3]

2. Definition of the problem

The cross-section considered for this study is shown in figure 1 given below:

Figure 1. Extruded cross-section with dimensions.

The optimum dimensions of thin-wall extruded cross-section are to be defined. The top surface is a
sheet of width ‘a’, and the two sides comprise of sheets of height ‘b’. The fourth side is an arc of
𝑎
radius ‘2’. The thickness is taken as ‘t’ for all the sheets. The ratio of thickness and length is a
constant, which serves as local stability conditions: [4]
𝑡 𝑡
𝑎
= 𝛿1 , 𝑏 = 𝛿2 .
Hence, we intend to define optimum dimensions of ‘a’ and ‘b’.
𝜋
Area of cross section: 𝐴 = 𝑎𝑡 + 2𝑏𝑡 + ( 2 ) 𝑡(𝑎 + 𝑡)
𝜋 𝜋
= (𝛿1 + 𝛿1 ) 𝑎2 + 2𝛿2 𝑏 2 + 𝛿1 𝛿2 𝑎𝑏
2 2
= 𝑘1 𝑎2 + 𝑘2 𝑏2 + 𝑘3 𝑎𝑏 (1)

where these substitutions are introduced:

2+𝜋 𝜋
𝑘1 = ( 2 ) 𝛿1 , 𝑘2 = 2𝛿2 , 𝑘3 = 2 𝛿1 𝛿2

3. Objective function and constraint function

If the material and length of structure are kept constant, then the area function can be taken as the
objective function (F).

𝐹 ≡ 𝐴 = 𝑘1 𝑎2 + 𝑘2 𝑏2 + 𝑘3 𝑎𝑏 (2)

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2nd International conference on Advances in Mechanical Engineering (ICAME 2018) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 402 (2018) 012134 doi:10.1088/1757-899X/402/1/012134
1234567890‘’“”

In order to form the constraint function, axial stress and bending are taken into consideration,
which are the major loads acting on a boom. Thus the constraint function is represented as a function
taking into consideration the failure parameters relevant for a crane boom:[5]

𝑁 𝑀 𝑀
𝜑= 𝐴
+ 𝑊𝑥 + 𝑊𝑦 − 𝑅𝑙 = 0 (3)
𝑥 𝑦

where, N - Axial force

𝑀𝑥 , 𝑀𝑦 - Moments of flexion about x and y axes
𝑊𝑥 , 𝑊𝑦 - Section modulus for corresponding axes
𝑅𝑙 - Limiting stress

The section modulus about x and y axes are represented as functions of cross section areas and
corresponding sides, as follows:

𝑎
𝑊𝑥 = 𝛼𝑥 (𝑏 + 2 ) 𝐴 , 𝑊𝑦 = 𝛼𝑦 𝐴𝑎 (4)

Thus, the constraint function can be represented as follows:

𝑁 𝑀𝑥 𝑀𝑦
𝜑=𝐴+ 𝑎 +𝛼 − 𝑅𝑙 = 0 (5)
𝛼𝑥 (𝑏+ )𝐴 𝑦 𝐴𝑎
2

Coefficients 𝛼𝑥 and 𝛼𝑦 have analytical values:

𝑊𝑥 𝐼𝑥
𝛼𝑥 = 𝑎
= 𝑎
(𝑏 + 2 ) 𝐴 (𝑏 + 2 ) 𝐴𝑦𝑚𝑎𝑥
2𝜋+1 2
𝑡[( 16
) 𝑎3 + 3 𝑏 3 + 7344.04𝑡 3 − 68.005𝑎2 𝑡 − 206.05𝑎𝑡 2 − 9626.067𝑏𝑡 2 ]
= 𝑎
69.376𝑡 (𝑏 + ) 𝐴
2

𝑊𝑦 𝐼𝑦
𝛼𝑦 = =
𝐴𝑎 𝐴𝑎𝑥𝑚𝑎𝑥
2 1 9 1 1 1
𝑡(3 𝑏𝑡 2 + 2 𝑎2 𝑏 + 𝑎𝑏𝑡 + 16 𝑎3 + 8 𝑎2 𝑡 + 4 𝑎𝑡 2 + 8 𝑡 3 )
= 𝑎
𝑎𝐴(2 )

𝑡 𝑡
Substituting the appropriate ratios of 𝑎 and 𝑏 as 𝛿1 and 𝛿2 respectively, and plugging in the values of
𝛿1 and 𝛿2 as 0.014 and 0.022 [5] respectively, we get:

42749.726 140506.1983 9365.91

𝛼𝑥 = (6.431 × 10−7 )( 3
+ 242954.325𝜀 3 + 7344.04 − −
𝜀 𝜀2 𝜀
− 687576.214𝜀)

52826 47209.44 2077.48

𝛼𝑦 = (1.4195 × 10−6 )(47.619𝜀 + + + + 0.125)
𝜀3 𝜀2 𝜀

For recommended range of 𝜀 = 0.65 to 0.80, hence the ratios of maximum and minimum values of
𝛼𝑥 and 𝛼𝑦 are as follows:

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2nd International conference on Advances in Mechanical Engineering (ICAME 2018) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 402 (2018) 012134 doi:10.1088/1757-899X/402/1/012134
1234567890‘’“”

𝛼𝑥𝑚𝑎𝑥 𝛼𝑦𝑚𝑎𝑥
𝛼𝑥𝑚𝑖𝑛
= 1.00343, 𝛼𝑦𝑚𝑖𝑛
= 1.71143 (6)

4. Mathematical modelling
The given parameters can be represented by a vector as: 𝑥⃑ = (𝐿, 𝑁, 𝑀𝑥 , 𝑀𝑦 , 𝑅𝑙 )

And vector of variables is: 𝑦⃑ = (𝑎, 𝑏)

To determine optimum parameters a0 and b0, the Lagrange multipliers method is used. In order to
minimize or maximize the function 𝐴 = 𝐴(𝑎, 𝑏) at a certain point, it is necessary to satisfy equations:

𝜕𝜑 𝜕𝜑
= 0, =0 (7)
𝜕𝑎 𝜕𝑏

The Lagrange function can be represented as:[6]

𝜑(𝑎, 𝑏, λ) = 𝐴(𝑎, 𝑏) + λ𝜑(𝑎, 𝑏) (8)

where λ is the unknown Lagrange’s multiplier. So the equation (8) can also be written as:

𝜕𝐴 𝜕𝜑 𝜕𝐴 𝜕𝜑
𝜕𝑎
+ λ 𝜕𝑎 = 0, 𝜕𝑏 + λ 𝜕𝑏 = 0 (9)

Combining the two equations, the multiplier λ can be eliminated as follows:[7]

𝜕𝐴 𝜕𝜑
+ λ =0
𝜕𝑎 𝜕𝑎
𝜕𝐴
−( )
𝑜𝑟, λ = 𝜕𝜑𝜕𝑎
( 𝜕𝑎 )
𝜕𝐴 𝜕𝜑
+ λ =0
𝜕𝑏 𝜕𝑏
𝜕𝐴 𝜕𝜑 𝜕𝐴 𝜕𝜑
𝑜𝑟, ( )( ) = ( )( ) (10)
𝜕𝑏 𝜕𝑎 𝜕𝑎 𝜕𝑏

5. Optimum parameters
Substituting equation (5) into equation (10) results into:
𝜕𝐴 𝑀𝑥 𝑀𝑦 𝜕𝐴 𝑀𝑥
[
𝜕𝑏 2𝛼 𝐴(𝑏+𝑎)2
+𝛼 2 ] = 𝜕𝑎 [ 𝑎 2
] (11)
𝑥 𝐴𝑎 𝛼𝑥 𝐴(𝑏+ )
𝑥 2 2
After substitution of expression (1) in expression (11), optimum relation of the sides a and b are as
follows:
𝑏𝑜 −4𝑘2 ±[16𝑘2 2 −16𝑘2 (2𝑘3 −4𝑘1 )] 1⁄2
ξ𝑜 = 𝑎𝑜
= 8𝑘2
= 0.53 (12)

The values of moment of flexion, axial force and other relevant parameters have been obtained from
[8,9]

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2nd International conference on Advances in Mechanical Engineering (ICAME 2018) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 402 (2018) 012134 doi:10.1088/1757-899X/402/1/012134
1234567890‘’“”

-𝑀𝑥 = 550 [𝑘𝑁𝑚], 𝑀𝑦 = 𝜓𝑀𝑥 , where 𝜓 = 0.40 − 0.75;

-Axial force is N=115 [kN];
-Limiting stress is 𝑅𝑙 = 196∆ [MPa], where coefficients of stress variation is
∆= 0.75 − 1.25
-Bending stress σ 𝑏 =115.11 [MPa]

Substituting the above values in (5), we get the optimum length of a, i.e. ‘𝑎0 ’:

𝑎0 = 0.4 𝑚

Substituting this value in ξ𝑜 , we get 𝑏0 = 0.212 𝑚

From the formulae, it is evident that the area of cross section is directly proportional to moment of
flexion, i.e. 𝐴0 = 𝑓(𝜓), for trapezium and box-rectangular cross-sections. The area of cross section is
found to be inversely proportional to the limiting stress. The variation has been depicted in the
following figures 2 and 3:

0.035

0.03

Area 0.025 Box

Trapezoid
0.02
Extruded

0.015
0.4 0.5 0.6 0.7
Ψ

Figure 2. Comparison of Surface Area of Box Rectangular, Trapezoid

and Extruded Cross-Sections of Boom with respect to 𝜑 .[10]

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2nd International conference on Advances in Mechanical Engineering (ICAME 2018) IOP Publishing
IOP Conf. Series: Materials Science and Engineering 402 (2018) 012134 doi:10.1088/1757-899X/402/1/012134
1234567890‘’“”

0.029

0.027

0.025

0.023
Area Box
0.021
Trapezoid
0.019 Extruded

0.017

0.015
0.9 1 1.1 1.2
Δ

Figure 3. Comparison of Surface Area of Box Rectangular, Trapezoid

and Extruded Cross-Sections of Boom with respect to ∆.[10]
6. Conclusion
In this paper, the optimum dimensions of a hollow extruded cross section for constructing the boom of
a mobile crane are defined. Simple formulae are derived in the analytical form, which can be put to
practical use when designing a crane. Comparison between the box section, trapezoidal section and the
extruded section has been performed from the point of view of minimizing area. By plotting the Area
vs Moment of flexion curves for all three cross sections, it is seen that the extruded section is more
economical than trapezoidal section for low values of moment of flexion. However, for greater values
of moment of flexion, the extruded section proves to be the least economical.

7. References

[1] Kumar N and Parvez M 2012 Force Distribution on Telescopic Boom of Crane, Int. J. Mech.
Eng. Robot. Res. 1
[2] Anon IS 4573: Specification for Power Driven Mobile Cranes
[3] Thomas Krebs B M and Irsch, Lebach; Karl-Heinz Rube, Zweibrücken all of G 2000 United
States Patent ( 19 ) 11 Patent Number : 6,098,824
[4] Ghosh S, Pati B, Ghosh R, Palo A and Student B T 2017 Static Analysis Of Crane Hooks With
Different Cross Sections – A Comparative Study Using Ansys, Int. J. Mech. Eng. Technol. 8,
474–82
[5] Šelmić R and Mijailović R 1998 Optimum Dimensions of Trapezium Cross-Section in
Structures, Ratko Šelmi ć , Radomir Mijailovi ć Sci. J. FACTA Univ. 1, 555–64
[6] Bertsekas D P 1996 Constrained Optimization and Lagrange Multiplier methods
[7] Pavlovic G, Gasic M, Rajovic M and Savkovic M 2013 Optimization of The Box Section of
the Main Girders of the Bridge Crane By Using The Method Of Lagrange.
[8] Kaur G 2016 Stress Analysis of a Boom of Pick-n-Carry Mobile Int. J. Sci. Res. 5
[9] Vanpariya P K B 2016 Design Analysis And Weight Optimization Of Lifting Hook, J. Emerg.
Technol. Innov. Res. 3, 81–5
[10] Sharma M and Sharma A 2017 Comparison of different Boom sections of Mobile, Int. J. Res.
Advent Technol. 5